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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 541 records · Page 30

Liquid-Cooled Heat Sink Optimization for Thermal Imbalance Mitigation in Wide-Bandgap Power Modules

Power semiconductor die placement on substrates used in high-power modules is generally optimized to minimize electrical parasitic (e.g., stray inductance, common-mode capacitance), taking into account the minimum spacing between semiconductor dies for thermal decoupling. The layout assumes sufficient heat spreading and transfer from dies to the cooling structure. Insulated metal substrate-based power module designs may lead to asymmetrical thermal resistance across the dies, which may cause significant temperature differences among the devices. Such unintentional thermal asymmetries can lead to oversizing the cooling system design or underusing the semiconductor power processing capability. This article proposes a thermal imbalance mitigation method that uses evolutionary optimized liquid-cooled heat sinks to improve the thermal loading among devices.

42 ENGINEERING↗

Control of Convection in Containerless Processing

Many different containerless processing techniques are employed in materials research, with the common goals of eliminating chemical reactions with the crucible and reducing heterogeneous nucleation sites. Each containerless method has different driving forces for flow in a liquid sample, and each has different relations between the flow variables and the process parameters. Often more than one technique is required to achieve the objectives of an experimental program. For example, one project requires solidification experiments over a range of almost two orders of magnitude in flow velocity, in both laminar and turbulent flow, while another requires a particular combination of shear rate and cooling rate, leading to a different processing strategy. The results of a modeling effort to determine the best combination of methods to meet the requirements of these two different experimental programs are presented.

Hyers, R. W.↗

Practical Considerations of Waste Heat Reuse for a Mars Mission Advanced Life Support System

Energy conservation is a key issue in design optimization of Advanced Life Support Systems (ALSS) for long-term space missions. By considering designs for conservation at the system level, energy saving opportunities arise that would otherwise go unnoticed. This paper builds on a steady-state investigation of system-level waste heat reuse in an ALSS with a low degree of crop growth for a Mars mission. In past studies, such a system has been defined in terms of technology types, hot and cold stream identification and stream energy content. The maximum steady-state potential for power and cooling savings within the system was computed via the Pinch Method. In this paper, several practical issues are considered for achieving a pragmatic estimate of total system savings in terms of equivalent system mass (ESM), rather than savings solely in terms of power and cooling. In this paper, more realistic ESM savings are computed by considering heat transfer inefficiencies during material transfer. An estimate of the steady-state mass, volume and crewtime requirements associated with heat exchange equipment is made by considering heat exchange equipment material type and configuration, stream flow characteristics and associated energy losses during the heat exchange process. Also, previously estimated power and cooling savings are adjusted to reflect the impact of such energy losses. This paper goes one step further than the traditional Pinch Method of considering waste heat reuse in heat exchangers to include ESM savings that occur with direct reuse of a stream. For example, rather than exchanging heat between crop growth lamp cooling air and air going to a clothes dryer, air used to cool crop lamps might be reused directly for clothes drying purposes. When thermodynamically feasible, such an approach may increase ESM savings by minimizing the mass, volume and crewtime requirements associated with stream routing equipment.

Levri, Julie↗

High density electronic packaging module with improved cooling assembly

Cold plate increases heat transfer within high density electronic module. Tapered pins improve heat transfer process by providing larger surface pressure with increased planar area. Cooling technique increases thermal contact where planar area is limited, interface pressure increases the heat transfer coefficient.

Martin, J. H.↗

Numerical simulation of warm fog and its application to warm fog prediction and modification

The considered theoretical model describes the evolution of potential temperature, water vapor content, liquid water content, and horizontal and vertical winds as determined by the processes of vertical turbulent transfer and horizontal advection for momentum, energy, and moisture, as well as radiation cooling, growth of water droplets based on microphysical processes, and drop sedimentation. The mathematical model is two-dimensional in the X-Z plane. The diffusivity coefficient is the same for liquid water droplets as for vapor. The fundamental equations governing the macrophysical processes of the evolution of wind components, water vapor content, liquid water content, and potential temperature under the influences of vertical turbulent diffusion transfer, turbulent momentum transfer, and turbulent energy transfer are expressed by three sets of conservation equations.

Hung, R. J.↗

Constraints on the Nature and Distribution of Iridium Host Phases at the Cretaceous-Tertiary Boundary: Implications for Projectile Identity and dispersal on impact

Among Cretaceous-Tertiary boundary sites worldwide, variations in the concentrations and ratios of elements commonly enriched in meteorites complicate traditional geochemical attempts at impactor identification. Yet they may provide constraints on the physical and chemical processes associated with large-body disruption and dispersal, as well as with diagenesis of projectile components. To this end, we continue our efforts to identify the mineral host-phases of projectile-derived elements, particularly for Ir, and to document their partitioning between crater deposits and ejecta resulting from the Chicxulub basin-forming impact. Building on earlier work, we used INAA to measure Ir concentrations in successively smaller splits of finely powdered impact melt breccia from the Chicxulub Crater in Mexico (sample Y6Nl9-R(b)), and K/T boundary fish clay from Stevns Klint, Denmark (sample FC-1, split from 40 kg of homogenized material intended as an analytical standard). Results for the Chicxulub sample show a heterogeneous Ir distribution and document that at least five discrete Ir-bearing host phases were isolated in subsequent splits, having Ir masses equivalent to pure Ir spheres from about 0.8 to about 3.5 mm in diameter. Three of these are within a sufficiently reduced mass of powder to warrant searching for them using backscattered electron microscopy. In contrast, successively smaller splits of the Stevns Klint fish clay show no statistically significant deviation from the reported value of 32 +/- 2 ng/g Ir, suggesting a uniform Ir host-phase distribution. For the smallest split obtained thus far (100 +/- 40 ng/g Ir), a pure Ir sphere of equivalent Ir mass would be <0.05 min in diameter. (n.b. Although homogenizing and sieving of FC-1 to <75 min obviously obscured variations in stratigraphic distribution, it is unlikely to have affected the size-frequency distribution of Ir host phases.) We previously identified micrometer-scale Ir host phases by electron microscopy in melt-rock samples from two widely separated drill holes at the Chicxulub Basin, including a replicate split of Y6-NI9-R. One is an aggregate of subhedral Ir metal grains enclosed in silicate, in which no other Pt group elements (PGE) were detected. A second particle with twice the mass as the first, concentrated predominantly in a single grain, is associated with minor concentrations of Os, Ru, and Pt, and with adhering particles of corundum and perovskite. A third Ir-rich particle, with a greater apparent Os concentration, was identified before being lost as a result of charging under the electron beam. In addition to demonstrating the preservation of projectile components within the Chicxulub Crater, analogous phase associations in Ca- and Al-rich inclusions (CAI) from C2 and C3 chondrites suggest to us that these melt-rock Ir host phases are relics from a carbonaceous chondrite K/T boundary impactor Although the obviously low Ru/Ir ratios of the Chicxulub Ir host phases are qualitatively consistent with suggested PGE fractionation with distance during condensation in an ejecta cloud, it seems difficult to explain the accumulation of the about 3 x 10(exp 11) Ir atoms required to form a about 10(exp -10) g nugget of pure Ir metal within a jet of vaporized projectile expanding at 1-4 km/s, or to effectively exclude or remove commonly alloyed PGE and siderophile elements by fractionation processes resulting from condensation, oxidation, sulfidization, exsolution, or autometamorphism during cooling of the melt. We do not dismiss the importance of these processes entirely; on the contrary, other geochemical and mineralogical aspects of the melt rocks require them, and condensation from the expanding ejecta cloud appears to best explain the primary Ir host-phase distribution in the fish clay, as well as the high Ir concentrations associated with spinel-bearing spheroids at the K/T boundary in the Pacific Ocean . If the "relict" hypothesis is correct, micronuggets of other PGEs and alloys, not detected by our INAA screening, should also occur in the melt rocks. Possibly, the discrete host phases with lesser Ir masses are such alloys with subordinate Ir, rather than simply smaller, predominantly Ir-bearing particles. A CAI source for the relics would be consistent with either a comet or an asteroid K/T impact at Chicxulub. (Additional information contained in the original.)

Schuraytz, B. C.↗

Impact of Rainfall on Tropical Cyclone-Induced Sea Surface Cooling

Tropical cyclones (TCs) are often accompanied by strong winds and torrential rains. While the winds associated with TCs tend to enhance mixing in the upper-ocean, the freshwater input from rain can stratify the water column and limit mixing. However, the extent to which the stabilizing effect of rainfall can compete with wind-induced mixing, and to what degree it modulates TC-induced sea surface cooling, remains unknown. Here we show, using a suite of observations, that heavy rains under weak TCs can significantly reduce the magnitude of cold wakes induced by them. Additionally, when compared to storms with low rain rates, the ocean surface under TCs with high rain rates freshens significantly and cools less. High-resolution climate model simulations and idealized experiments with an ocean mixed layer model support these results and reveal that oceanic mixing processes are primarily responsible for the reduced cooling under TCs, with a lesser role for surface fluxes.

54 ENVIRONMENTAL SCIENCES↗

Neutrino signal from proto-neutron star evolution: Effects of opacities from charged-current–neutrino interactions and inverse neutron decay

In this work, we investigate the impact of charged-current–neutrino processes on the formation and evolution of neutrino spectra during the deleptonization of proto-neutron stars. To this end we develop the full kinematics of these reaction rates consistent with the nuclear equation of state, including weak magnetism contributions. This allows us to systematically study the impact of inelastic contributions and weak magnetism on the $ν_e$ and $\bar{ν}_e$ luminosities and average energies. Furthermore, we explore the role of the inverse neutron decay, also known as the direct Urca process, on the emitted spectra of $\bar{ν}_e$. This process is commonly considered in the cooling scenario of cold neutron stars but has so far been neglected in the evolution of hot proto-neutron stars. We find that the inverse neutron decay becomes the dominating opacity source for low-energy $\bar{ν}_e$. Accurate three-flavor Boltzmann neutrino transport enables us to relate the magnitude of neutrino fluxes and spectra to details of the treatment of weak processes. This allows us to quantify the corresponding impact on the conditions relevant for the nucleosynthesis in the neutrino-driven wind, which is ejected from the proto-neutron star surface during the deleptonization phase.

79 ASTRONOMY AND ASTROPHYSICS↗

Solar heating and cooling technical data and systems analysis

The acquisition and processing of selected parametric data for inclusion in a computerized Data Base using the Marshall Information Retrieval and Data System (MIRADS) developed by NASA-MSFC is discussed. This data base provides extensive technical and socioeconomic information related to solar energy heating and cooling on a national scale. A broadly based research approach was used to assist in the support of program management and the application of a cost-effective program for solar energy development and demonstration.

Christensen, D. L.↗

Incoherent Dynamics of Intense Proton Beams under Electron Cooling

The minimum emittance of ion beams achieved using electron cooling is limited by the heating processes of Intra Beam Scattering and diffusion driven by resonance crossing of particles due to space-charge. We describe a new experiment to explore the intense space-charge regime with a transverse tune shift approaching -0.5 using 2.5~MeV protons at the Integrable Optics Test Accelerator (IOTA) at Fermilab. We also report on the results from PyORBIT simulations incorporating transverse space-charge and electron cooling with emphasis on the incoherent dynamics of the particles.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Incoherent Dynamics of Intense Proton Beams Under Electron Cooling

The minimum emittance of ion beams achieved using electron cooling is limited by the heating processes of Intra Beam Scattering and diffusion driven by resonance crossing of particles due to space-charge. We describe a new experiment to explore the intense space-charge regime with a transverse tune shift approaching -0.5 using 2.5 MeV protons at the Integrable Optics Test Accelerator (IOTA) at Fermilab. We also report on the results from PyORBIT simulations incorporating transverse space-charge and electron cooling with emphasis on the incoherent dynamics of the particles.

43 PARTICLE ACCELERATORS↗

Build plate conduction cooling for thermal management of wire arc additive manufactured components

Wire arc additive manufacturing (WAAM) allows for quick, large component manufacturing with fast deposition rates while leveraging readily available wire feedstock that is significantly cheaper than metal powder. However, the increased deposition rate of this process requires enhanced thermal management as failures can occur due to overheating. A common strategy to mitigate overheating is to dwell, or pause, between individual layers; however, this can significantly increase build times and eliminate the advantage of additive manufacturing being able to manufacture components quickly. To help mitigate this issue, this study explores the use of active cooling to maintain process control and to decrease overall build time. In this work, conductive cooling applied to either the bottom or side of the print substrate was explored. Results from this study showed that bottom build plate active cooling can be used to decrease dwell times by up to 50% and decrease cool-down to room temperature after the building process by up to 75%. Results from this study demonstrate that the use of active cooling strategies for WAAM can be used for better thermal control over the process and should be further investigated.

36 MATERIALS SCIENCE↗

Cutoff and Emergence of Dart Leaders in an Unbranched Positive Leader Simulation

Channel cutoff is the process by which an active lightning channel cools down, goes dark, and loses its ability to effectively conduct electricity. Current cutoff precedes several lightning phenomena, notably dart leaders and return strokes, but the process by which a hot, highly‐conducting leader channel can undergo current cutoff is poorly understood. In this work, we present self‐consistent simulations of positive leader propagation, which include coupled treatment of electrodynamics and plasma physics. The unstable positive leader spontaneously undergoes channel cutoff and creates the conditions for the emission of dart leaders, that is, it accumulates a packet of negative charge at the intersection between cutoff and conducting channel segments. A residual conductivity in the cutoff section facilitates the conversion of the electric field enhancement into a traveling wave, which retraces and reionizes the channel. This is critical for allowing the frail positive leader to keep propagating.

58 GEOSCIENCES↗

Direct Observation of Two-Step, Stratified Crystallization and Morphology in Conjugated Polymer Thin Films

A two-step stratified crystallization process has been directly observed during cooling of poly(3-hexylthiophene) (P3HT) thin films of thickness h = 20-250 nm: a thin (<20 nm) layer at the free surface crystallizes ~25 °C higher than the bulk crystallization temperature (T C,bulk ), whereas the rest of the film (i.e. the underlayer) crystallizes near T C,bulk . In-situ measurements of films with and without a free surface unequivocally ascribe the high-temperature crystallization to a surface-induced process, which correlates with the formation of large birefringent structures and highly oriented edge-on crystallites at the air–polymer interface. In contrast, crystallization of the bulk-like underlayer leads to mostly edge-on-oriented crystallites in thinner films and becomes increasingly isotropic in thicker films. For h < 20 nm, free-surface effects dominate and only high-temperature crystallization is observed. These results highlight the potential of melt crystallization to tailor morphology and orientation across thin film thickness for specific electronic applications.

36 MATERIALS SCIENCE↗

A comparison of FeO-rich, porphyritic olivine chondrules in unequilibrated chondrites and experimental analogues

Experimentally produced analogues of porphyritic olivine (PO) chondrules in ordinary chondrites provide an important insight into chondrule formation processes. We have studied experimental samples with PO textures grown at three different cooling rates (2, 5 and 100 C/h), and samples that have been annealed at high temperatures (1000-1200 C) subsequent to cooling. These are compared with natural chondrules of similar composition and texture from the ordinary chondrites Semarkona (LL3.0) and ALH 81251 (LL3.3). Zoning properties of olivine grains indicate that the Semarkona chondrules cooled at comparable rates to the experiments. Zoning in olivine from chondrules in ALH 81251 is not consistent with cooling alone but indicates that the chondrules underwent an annealing process. Chromium loss from olivine is very rapid during annealing and calculated diffusion coefficients for Cr in olivine are very similar to those of Fe-Mg interdiffusion coefficients under the same conditions. Annealed experimental samples contain an aluminous, low-Ca pyroxene which forms by reaction of olivine and liquid. No similar reaction texture is observed in ALH 81251 chondrules, and this may be evidence that annealing of the natural samples took place at considerably lower temperatures than the experimental analogues. The study supports the model of chondrule formation in a cool nebula and metamorphism of partly equilibrated chondrites during reheating episodes on the chondrite parent bodies.

Jones, Rhian H.↗

Finding the Cold Needle in a Warm Haystack: Infrared Imaging Applied to Locating Cryo-cooled Crystals in Loops

Thermally imaging the cryocooling processes of crystals has been demonstrated showing the progression of a cold wave through a crystal from the face closest to the origin of the coldstream ending at the point furthest away. During these studies large volume crystals were clearly distinguished from the loop holding them. Large volume crystals, used for neutron studies, were chosen deliberately to enhance the imaging. The different infrared transmission and reflectance properties of the crystal in comparison to the cryo-protectant are thought to be the parameter that produces the contrast making the crystal visible. As an application of the technology to locating crystals, more small crystals of lysozyme and a bFGF/dna complex were cryo-protected and imaged in large loops. The crystals were clearly distinguished from the vitrified solution. In the case of the bFGF/dna complex the illumination had to be carefully manipulated to enable the crystal to be seen in the visible spectrum. These preliminary results will be presented along with advantages and disadvantages of the technique and a discussion of how it might be applied.

Snell, Edward↗

Experimental study of a tri-functional propane hydronic heat pump

This study investigates the performance of a propane hydronic heat pump system for space cooling, heating, and water heating applications, focusing on various operational conditions, with a total refrigerant charge below 1200 g. Cooling performance was evaluated at different outdoor temperatures, compressor stages (capacity levels), and water flow rates. The results showed that the coefficient of performance (COP) for cooling was higher at lower outdoor temperatures, with peak values exceeding 5.0 under low-stage operation and lower water flow rate. The cooling capacity increased with higher flow rates and compressor stages, reaching 12 kW. Space heating performance, evaluated at ambient temperatures ranging from −8.3 °C to 16.7 °C, revealed a decrease in COP with lower temperatures. However, high-stage operation maintained higher heating capacities even at low temperatures. The system demonstrated high Heating Seasonal Performance Factors (HSPF), exceeding 10.0. For water heating, the COP decreased with lower ambient temperatures and higher supply water temperatures. The system efficiently heated an 189-L water tank, outperforming conventional water heaters, with process COPs exceeding 4.0 under cooling-season conditions. Despite some efficiency loss due to defrosting at low temperatures, the propane heat pump consistently delivered strong performance. Seasonal energy efficiency ratios (SEER) and seasonal heating COP values indicated significant overall efficiency. The study concludes that propane is a promising refrigerant for heat pump systems, with future research needed to future reduce total system charge and optimize system performance through advanced controls and heat exchanger designs.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗